Energy Storage Busbar Assembly Same-Side Bonding
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Solution Overview
Problem
The production of energy storage arrangements for electric vehicles is time-consuming and error-prone due to the complexity of bonding processes, especially with small-diameter wires, and requires moving the energy storage or bonding tool during the fastening process.
Innovation Solution
The energy storage arrangement features busbars fastened on the same end side of each energy storage, with the first busbar connected to the terminal connection and the second busbar connected to the housing, eliminating the need for movement and using welding connections for a more robust mechanical link, and incorporating cup-shaped housings with cover elements for insulation and space-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonding methods are used to electrically conductively fasten busbars on opposing end sides of cylindrical energy storages, then electrical connections can be realized, but the production process becomes very time consuming and error prone
Solution Approach 1:
Instead of bonding busbars to terminal connections on opposing end sides (conventional approach), the patent inverts the approach by bonding both busbars to terminal connections on the same end side. This allows the energy storage to remain stationary during assembly, dramatically improving productivity while maintaining connection reliability through the same bonding technology.
Solution Approach 2:
The terminal connection is designed to provide both electrical and mechanical connection functions in advance. By preparing the terminal connection with integrated bonding surfaces and structural features, the patent eliminates the need for subsequent positioning and movement operations, allowing direct bonding of both busbars in a single assembly step.
2Reliability
If bonding processes are used with small diameter wires, then electrical connections can be established, but the process becomes error prone and time consuming
Solution Approach 1:
The terminal connection acts as an intermediary component that simplifies the bonding process. Instead of directly bonding small-diameter wires to the busbars (which is error-prone), the terminal connection provides enlarged bonding surfaces and structural support, making the manufacturing process easier and more reliable while maintaining electrical connection stability.
3Ease of manufacture
If energy storage arrangement or bonding tool must be moved during fastening process, then bonding of busbars on opposing end sides can be accomplished, but production becomes technically complicated
Solution Approach 1:
The patent inverts the conventional assembly approach by arranging both busbar connections on the same end side instead of opposing end sides. This spatial reconfiguration allows the energy storage to remain stationary throughout the bonding process, eliminating the need for complex movement mechanisms and significantly reducing production system complexity.
4Productivity
If busbars are arranged on same end side of energy storage, then movement during production is eliminated, but electrical insulation between busbars must be provided
Solution Approach 1:
The terminal connection merges multiple functions into a single component: it provides electrical connection, mechanical support, and electrical insulation. By integrating the insulation function directly into the terminal connection structure (which bonds both busbars), the patent achieves high assembly efficiency without adding separate insulation components or increasing overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the production process, reduces errors, and creates a more cost-effective and robust energy storage arrangement, allowing for efficient assembly without mechanical weak points, suitable for various applications including motor vehicles and stationary use.
Implementation Method 1
a first busbar electrically conductively fastened on the terminal connection of each of the energy storages, and a second busbar electrically conductively fastened on the housing on the end side of the energy arrangement on which the first busbar is arranged
Data Source
AI summary
An energy storage arrangement, includes multiple energy storages, each energy storage having a housing and a terminal connection, wherein the terminal connection lies on an electrostatic potential of a first terminal of the energy storage and is arranged on an end side of the energy storage, wherein the housing lies on an electrostatic potential of a second terminal of the energy storage. The energy storage arrangement further has a first busbar electrically conductively fastened on the terminal connection of each of the energy storages, and a second busbar electrically conductively fastened on the housing on the end side of the energy arrangement on which the first busbar is arranged.